Method of manufacturing lamp socket assemblies

ABSTRACT

A lamp socket having a center conductor pin fixed in the insulator and socket sleeve. An additional terminal in the socket assembly adjacent the center pin for tying the wire going to the pin. A socket assembly including an illuminated panel, color filter and heat sink. A method of forming a socket sleeve for bayonet base lamps.

United States Patent Original application Jan. 22, 1968, Ser. No. 699,505, now Patent No. 3,506,934. Divided and this application Jan. 12, 1970, Ser. No. 002,265

METHOD OF MANUFACTURING LAMP SOCKET ASSEMBLIES 2 Claims, 9 Drawing Figs.

U.S.Cl 113/119 B2111 53/36 [50] Field of Search 113/119; 339/188 R, 189 R, 190 B, 188 T, 189 L; 72/348 [56] References Cited UNITED STATES PATENTS 2,941,182 6/1960 Heller 339/188 2,965,965 12/1960 Allan 113/119 3,435,792 4/1969 Olson 113/119 Primary Examiner-Richard J. Herbst Attorney-l-larris, Kiech, Russell & Kem

ABSTRACT: A lamp socket having a center conductor pin fixed in the insulator and socket sleeve. An additional terminal in the socket assembly adjacent the center pin for tying the wire going to the pin. A socket assembly including an illuminated panel, color filter and heat sink. A method of forming a socket sleeve for bayonet base lamps.

22232 was a PATENTED SEP28 ISYI SHEET 1 OF 2 FIG. .3.

I, n N42 FIG.

E 5 m M MN m M J 5) M5 ATTOE/VEYS HARE/57 K/EcH, Passe-1.1. & KER/V I PATEN'TEDSEP28IQYI 3.608.508

SHEUZUFZ 67 f? 70 g FIGAZ. 55 l\ l 65 JAMES IV. DUPREE 5 H/S ATTOEA/E rs HARE/57 K/ECH, Russeu. & KEEN METHOD OF MANUFACTURING LAMP SOCKET ASSEMBLIES This application is a division of my copending application on Lamp Socket Assembly, Ser. No. 699,505, filed Jan. 22, I968, now U.S. Pat. No. 3,506,934.

This invention relates to sockets for electric lamps and in particular, to new and improved manufacturing of sockets and socket assemblies, particularly adapted for use with lamps having spring loading moving contact pins.

It is a particular object of the invention to provide a new and improved method of forming socket sleeves for receiving bayonet base type lamps.

The novel method of the invention will more fully appear in the course of the following description. The drawings merely show and the description merely describes a preferred embodiment of the present invention which is given by way of iilustration or example.

In the drawings:

FIG. 1 is a side view of a lamp and socket mounted in a panel and incorporating a socket sleeve manufactured in accordance with a preferred embodiment of the present invention; 7

FIG. 2 is an enlarged view partly in section taken along the line 2-2 of FIG. 1;

FIG. 3 is a sectional view of the socket of FIG. 2 prior to installation in the panel;

FIG. 4 is a view similar to that of FIG. 1 showing an alternative panel arrangement;

FIG. 5 is an enlarged view partly in section of the lamp and socket of FIG. 4;

FIG. 6 is a side view, partly in section, showing a partially formed socket sleeve;

FIG. 7 is a sectional view taken along the line 7-7 of FIG.

FIG. 8 is a view similar to that of FIG. 6 showing the socket sleeve following the next step in its manufacture; and

FIG. 9 is a sectional view taken along the line 9--9 of FIG. 8.

Referring to the structures of FIGS. 1, 2 and 3, a lamp socket 20 is mounted in a panel 21 and a lamp 22 is installed in the socket. The socket includes a metal sleeve 23, an insulator 24, and a metal pin 25. The insulator 24 is molded about the pin 25, with the inner end 26 of the pin exposed and with the outer end 27 of the pin projecting from the insulator. The insulator 24 is positioned within the sleeve 23 with a shoulder 30 of the insulator engaging a mating shoulder 31 of the sleeve. The sleeve may be crimped or dimpled at 32 to retain the insulator and pin. The pin and insulator may also be fastened in the sleeve by cementing, as at 35.

The lamp 22 has a bayonet-type base and the sleeve 23 is provided with opposed .l-shaped protrusions 33 for receiving and retaining the lamp. The socket is particularly adapted for use with lamps having a spring loaded moving contact pin, such as is described in applicants copending application Ser. No. 650,518, filed June 30, 1967, now US. Pat. No. 3,530,330. The moving pin 34 of the lamp 22 engages the end 26 of the pin 25 of the socket.

The panel 21 typically may be a relatively thick plastic sheet 36 with a thin metal layer 37 on one face. The socket sleeve as illustrated in FIG. 3 has an annular section 40 which is positioned in an opening in the panel 21. An elongate terminallike member 41 has an opening 42 at one end thereof. This member 41 is positioned over the section 40 of the sleeves and the socket is fixed in the panel, as by spinning over or swagging the end of the sleeve, as illustrated at 43 in FIG. 2. The socket may be soldered to the metal sheet 37 for additional security. i

A wire 46 is fastened to the socket by wrapping the bare end 47 around the pin end 27 and soldering the parts together. The conductor 46 is also fastened to the member 41, as by tying with a cord 48.

The lamp 22 is electrically energized via the metal sheet 37 and the socket sleeve 23, and via the wire 46 and socket pin 25. Typically, the metal sheet 37 will be the ground side and the wire 46 will be the hot side.

The pin 25 is fixed in the socket 20 so that there is no movement of any portion of the socket when a lamp is installed or removed. This absence of moving parts and motion in the socket eliminates most problems arising from connection of the flexible wire 46 to the pin 25 of the socket 20. Also, since the pin is fixed in the socket, there are no openings through the socket and no moisture paths exist from one side of the panel to the other. The structure incorporates an additional safety feature by providing for tying down of the wire 46 closely adjacent the solder connection so that if for any reason the connection comes loose or the wire breaks at the solder joint, the hot wire will not be free to move around. Of course, the terminal member 41 may be used for a wire conductor to the socket sleeve, if desired.

An alternative form for the lamp socket is illustrated in FIGS. 4 and 5, wherein elements corresponding to those of FIGS. 1 through 3 are identified by the same reference numerals. A socket is mounted in a panel 49 and a lamp 22 is carried in the socket. The panel 49 may be similar to the panel 21 or may be a metal panel as illustrated. The socket 50 may be an assembly comprising the sleeve 23, the insulator 24 and the pin 25 mounted in an opening SI in the bottom of a housing 52, with the member 41 clamped to the housing 52 by the spun over end of the sleeve 23. The sleeve 23, insulator 24 and pin 25 may be the same as that comprising the socket 20 of FIG. 3. In an alternative form of construction, the insulator 24 may be a machined item with the pin 25 positioned in a central opening thereof and fixed by peening or rolling at the inner end 26.

The housing 52 has an annular flange 55 which may restin a counterbore 56 of the panel 21 to provide a flush installation for the socket. An antirotation tab 57 may be provided in the flange 55 for engaging the panel and locking the socket in place. The socket is held in the panel opening by a washer 58 and nut 59 engaging the threaded outer portion of the housmg.

Another panel may be positioned against the panel 49, with an opening 66 for receiving the lamp 22. The panel 65 typically may be of a clear plastic providing for light conduction therethrough and the upper surface 67 may have an opaque coating with characters cut therein to provide a lighted display. When desired, a sleeve or cup-shaped member 68 may be positioned in the opening 66, with the lamp 22 projecting into the interior of the member 68. The member 68 typically may be of colored plastic selected to provide a desired color for the illumination in the panel 65. A metal plate 70 may be positioned at the bottom of the opening 66 between the panel 65 and the member 68 to serve as a heat sink aiding the dissipation of heat from the lamp 22. The size and configuration of the opening 66 may be varied depending on whether or not the member 68 is to be utilized. The metal plate 70 also aids in dispersing the illumination from the lamp and prevents a high-intensity spot over the lamp.

The metal sleeve 23 with the J-shaped protrusions 33 is formed from an intermediate sleeve 72, illustrated in FIG. 6. The intermediate sleeve 72 has the annular section 40, another larger annular section 73, and an end section 74. The end section 74 has opposed segments 75, 76 of the same radius as the section 73, and opposed segments 77, 78 of a greater radius. The intermediate sleeve 72 may be produced by various conventional manufacturing processes, such as by eyeleting from sheet stock, by expanding from tubular stock, by rolling and seaming from sheet stock, and the like. The protrusions 33 are then formed by pressing a portion of the segments 77, 78'inward to the radius of the section 73. This may be performed by inserting a mandrel into the sleeve and externally applying compression forces with dies. This method of forming the protrusions 33 for receiving the bayonet base of the lamp 22 permits simple, accurate and inexpensive sleeve manufacture at high-production rates.

Although an exemplary embodiment of the invention has segments of a second larger radius; and been disclosed and discussed, it will be understood that this pressing a portion of each of said third and fourth segments embodiment may be subjected to various changes, modificainward to said first radius, each of said portions leaving a tions and substitutions without necessarily departing from the pr i n the Segment n 111 nfig r ion f the s irit of the invention. letter J for receiving and retaining a lamp with a bayonetclaim: type base.

1, A method of making a leeve for a bayonet lam ocket 2. A method 3.5 defined in claim 1 in which said forming step includes forming the tube with a third section of a third radius less than said first radius, and with said first section interlO mediate said second and third sections.

including the steps of:

forming a tube with a first section of a first radius and a second adjacent section with first and second opposed segments of said first radius and third and fourth opposed UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,608,508 Dated Sept. 28, 1971 Inventor(s) James N. Du aree It is certified that error appears in the above-identified patent at; that said Letters Patent are hereby corrected as shown below:

stract pa e:

Col. 1, 1. "assignee Western Indicator Co., Inc." should be --assignee Dupree, Inc."

Col. 1, 1. 11 "Pat. No. 3,506,934" should be --Pat. No.

3,506,943-. Col. 1, l. 5 "Pat. No. 3,506,934" should be "Pat. No.

3,506,943" Col. 1, l. 63 "term1nall1ke should be --terminallike-- Col. 1, l. 67 "swagging" should be --swaging-- Signed and sealed this 13th day of June 1972.

(SEAL) Attest:

EDWARD M.FLETCI'IER,JR. ROBERT GOTTSCHALK Attesting Officer Commissioner of Patents OHM (19-69) uscoMM-oc 60376-P69 9 U S GQVEHNMENT PRINTING OFFICE! l9! 0-IQ-Sll 

1. A method of making a sleeve for a bayonet lamp socket, including the steps of: forming a tube with a first section of a first radius and a second adjacent section with first and second opposed segments of said first radius and third and fourth opposed segments of a second larger radius; and pressing a portion of each of said third and fourth segments inward to said first radius, each of said portions leaving a protrusion in the segment in the configuration of the letter J for receiving and retaining a lamp with a bayonet-type base.
 2. A method as defined in claim 1 in which said forming step includes forming the tube with a third section of a third radius less than said first radius, and with said first section intermediate said second and third sections. 